Prestressing

1800

Prestressing
Section 1800 Prestressing

1801 DESCRIPTION

Structural concrete containing prestressed steel reinforcement to introduce precompression

is termed as prestressed concrete.

The work shall be carried out in accordance with the drawings and these Specifications or
as approved by the Engineer.

Concrete and untensioned steel for the construction of prestressed concrete members
shall conform to the requirements of sections 1700 and 1600 for Structural Concrete and
Steel Reinforcement respectively in so far as the requirements of these Sections apply
and are not specifically modified by requirements set forth herein.

1802 MATERIALS

1802.1 All materials shall conform to Section 1000.

1802.2 Sheathing

1802.2.1 The sheathing ducts shall be of the spiral corrugated type either in mild steel
or in HDPE. They shall be in as long lengths as practical from handling and transportation
considerations without getting damaged.

M.S. Sheathing ducts

The material shall be Cold Rolled Cold Annealed (CRCA) Mild Steel conforming to IS:513
intended for mechanical treatment and surface refining but not for quench hardening or
tempering.

The material shall be clean and free from rust and normally be bright finished. However,
where specified, as in case of use in aggressive environment, galvanized or lead-coated
mild steel strips shall be used.

The thickness of sheathing shall be as shown on the drawing, but shall not be less than 0.3
mm, 0.4 mm and 0.5 mm for sheathing ducts having internal diameter of 50 mm, 75 mm
and 90 mm respectively. For larger diameter of ducts, thickness of sheathing shall be
based on recommendations of prestressing system supplier or as directed by the Engineer.

The sheathing shall conform to the requirement specified in Appendix 1A of IRC:18. All
the joints of sheathing shall be water tight and conform to provisions contained in
Appendix 2 of IRC:18.

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Corrugated HDPE sheathing ducts

The material for the ducts shall be high-density polyethylene withmore than 2 percent carbon
black to provide resistance to ultraviolet degradation and shall have the following properties:

Specific Density : 0.954 g/cm3 at 230C

Yield Strength : 18.0 N/mm2
Tensile Strength : 21.0 N/mm2
Shore Hardness D-3 sec. value : 60
-15 sec. value : 58
Notch impact strength at 230C : 10 kJ/m2
-400C : 4 kJ/m2
Coefficient of Thermal
Expansion for 200C – 800C : 1.50 x 10-4 kJ/m2

The thickness of the wall shall be 2.3+ 0.3 mm as manufactured and 1.5 mm after loss in
the compression test, for duct size upto 160 mm OD.

The ducts shall be corrugated on both sides. The ducts shall transmit full tendon strength
from the tendon to the surrounding concrete over a length not greater than 40 duct diameters.

These ducts shall be joined by adopting any one or more of the following methods, as
convenient to suit the individual requirements of the location, subject to the satisfactory
pressure tests before adoption.

Screwed together with male and female threads.

Joining with thick walled HDPE shrink couplers with glue. This can also be used for
connection with trumpet etc.

Welding with electrofusion couplers.

The joints shall be able to withstand an internal pressure of 0.5 bar for 5 minutes as per
test procedure given in Appendix II of IRC:18.

For major projects, the sheathing duct should preferably be manufactured at the project
site utilizing appropriate machines. With such an arrangement, long lengths of sheathing
ducts may be used with consequent reduction in the number of joints and couplers. Where
sheathing duct joints are unavoidable, such joints shall be made slurry tight by the use of
corrugated threaded sleeve couplers which may be tightly screwed onto the outer side of
the sheathing ducts.

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Section 1800 Prestressing

The length of the coupler should not be less than 150 mm but should be increased upto
200 mm wherever practicable. The joints between the end of coupler and duct shall be
sealed with heat shrink tape to prevent penetration of slurry during concreting. The couplers
of adjacent ducts shall be staggered wherever practicable. As far as possible, couplers
should not be located in curved zones. The corrugated sleeve couplers are being
conveniently manufactured using the sheath making machine with the next higher size of
die set.

1802.2.2 The internal area of the sheathing duct shall be in accordance with the
recommendations of the system manufacturer and shall be about three times the area of
the tendons. In case of 6T13, 12T13 and 19T13 size of tendons comprising 12/13 mm dia
strands, the inner diameter of the sheathing shall not be less than 50 mm, 75 mm and 90
mm respectively or those shown in the drawing, which ever is greater.

Where prestressing tendons are required to be threaded after concreting, a temporary

tendon shall be inserted in the sheathing or the sheathing shall be stiffened by other suitable
method during concreting.

1802.3 Anchorages

1802.3.1 Prestressing accessories like jacks, anchorage, wedge, block plate, etc.
being patended items shall be procured from authorized manufacturers only. Anchorages
shall conform to BS:4447. The prestessing accessories shall be subjected to an acceptance
test prior to their actual use on the work. Test certificates from a laboratory fully equipped
to carry out the tests shall be furnished to the Engineer. Such test certificates shall not be
more than 12 months old at the time of making the proposal for adoption of a particular
system for the project.

No damaged anchorages shall be used. Steel parts shall be protected from corrosion at
all times. Threaded parts shall be protected by greased wrappings and tapped holes
shall be protected by suitable plus until used. The anchorage components shall be kept
free from mortar and loose rust and any other deleterious coating.

1802.3.2 Swages of prestressing strand and button-heads of prestressing wire, where

provided shall develop a strength of at least 95 percent of the specified breaking load of
the strand or wire as the case may be. Where swaging/button-heading is envisaged, the
Contractor shall furnish details of his methodology and obtain approval of the Engineer,
prior to his taking up the work.

1802.3.3 Untensioned steel reinforcements, around anchorages shall conform to the details
of prestressing system and as shown on the drawing.

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1802.4 Couplers

Coupling units and other similar fixtures used in conjunction with the prestressing strands
or bars shall have an ultimate tensile strength of not less than the individual strengths of the
strands or bars being joined.

1803 TESTING OF PRESTRESSING STEEL AND ANCHORAGES

All materials specified for testing shall be furnished free of cost and shall be delivered in
time for tests to be made well in advance of anticipated time of use.

All wire, strand or bars to be shipped to the site shall be assigned a lot number and tagged
for identification purposes. Anchorage assemblies to be shipped shall be like-wise
identified.

All samples submitted shall be representative of the lot to be furnished and in the case of
wire or strand, shall be taken from the same master roll. The Contractor shall furnish
samples of at least 5.0 m in length selected from each lot for testing. Also, two anchorage
assemblies, complete with distribution plates of each size or types to be used, shall be
furnished alongwith short lengths of strands as required.

1804 WORKMANSHIP

1804.1 Cleaning

Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other deleterious
substance.

Cleaning of the steel may be carried out by immersion in suitable solvent solutions, wire
brushing or passing through a pressure box containing carborundum powder. However,
the tendons shall not be brought to a polished condition.

1804.2 Straightening

High tensile steel wire and strand shall be supplied in coils of sufficiently large diameter
such that tendons shall retain their physical properties and shall be straight as it unwinds
from the coil. Tendons of any type that are damaged, kinked or bent shall not be used.

The packing of prestressing wire/strand shall be removed only just prior to making of cable
for placement. Suitable stands shall be provided to facilitate uncoiling of wires/strands

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Section 1800 Prestressing

without damage to steel. Care shall be taken to avoid the possibility of steel coming into
contact with the ground.

1804.3 Positioning

1804.3.1 Post-Tensioning

Prestressing tendons shall be accurately located and maintained in position, both vertically
and horizontally, as per drawings.

Tendons shall be so arranged that they have a smooth profile without sudden bends or
kinks.

The locationing of prestressed cables shall be such as to facilitate easy placement and
vibration of concrete in between the tendons. High capacity tendon shall be used to reduce
the number of cables thereby eliminating the necessity of grouping. The selected profiles
of the tendons shall be such that their anchorages are not located in the top deck surface.
Where two or more rows of cables have to be used, the cables shall be vertically in line to
enable easy flow. Two cables shall in no case be less than 100 mm anywhere along the
length of the superstructure. Where precast segments are used, the clear distance shall
be at least 150 mm.

Sheathing shall be placed in correct position and profile by providing suitable ladders and
spacers. Such ladders may be provided at intervals of approximately 1.0 m. Sheathing
shall be tied rigidly with such ladders/spacer bars so that they do not get disturbed during
concreting.

The method of supporting and fixing shall be such that profile of cables is not disturbed
during vibrations, by pressure of wet concrete, by workmen or by construction traffic.

Sheathing in which the permanent tendon will not be in place during concreting shall have
a temporary tendon inserted or shall be stiffened by some other method to the approval of
the Engineer. The temporary tendon shall be pulled out before threading the permanent
tendon into place by a special threading machine or other contrivance.

Where possible tendons shall not be placed until immediately prior to stressing. Tendons
shall be handled with care to avoid damage or contamination, to either the tendon or the
sheathing. Any tendons damaged or contaminated shall be cleaned or replaced.

1804.3.2 Pre-Tensioning : Prestressing steel shall be accurately located and

maintained in position, both vertically and horizontally, as per drawings.

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1804.3.3 Each anchorage device shall be set square to the line of action of the
corresponding prestressing tendon and shall be positioned securely to prevent movement
during concreting.

The anchorage devices shall be cleaned to the satisfaction of the Engineer prior to the
placing of concrete. After concreting, any mortar or concrete which adheres to bearing or
wedging surfaces, shall be removed immediately.

1804.4 Cutting

Cutting and trimming of wires or strands shall be done by suitable mechanical or flame
cutters. When a flame cutter is used, care shall be taken to ensure that the flame does not
come in contact with other stressed steel. The location of flame cutting of wire or strand
shall be kept beyond 75 mm of where the tendon will be gripped by the anchorage or
jacks.

In post-tensioning the ends of prestressing steel projecting beyond the anchorages, shall
be cut after the grout has set.

1804.5 Protection of Prestressing Steel

Prestressing steel shall be continuously protected against corrosion, until grouted. The
corrosion protector shall have no deleterious effect on the steel or concrete or on the bond
strength of steel to concrete. Grouting shall conform to these Specifications or as directed
by the Engineer.

In the case of external prestressing, steel shall be encased in suitable polyethelene pipes
before grouting.

1804.6 Sheathing

The joints of all sheathings shall be water-tight. Special attention shall be paid to the
junction at the anchorage end, where the sheathing must tightly fit on the protruding trumpet
end of anchorage and thereafter sealed preferably with heat shrink tape, to make it water-
proof.

The heat-shrink tape is supplied in the form of bandage rolls which can be used for all
diameters of sheathing ducts. The bandage is coated on the underside with a heat sensitive
adhesive so that after heating the bandage material shrinks on the sheathing duct and
ensures formation of a leak-proof joint. The heating is effected by means of a soft gas
flame.

A sheath making machine should be positioned at the site of work for large projects so
that sheathing can be prepared as and when it is required for construction.

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Section 1800 Prestressing

The sheathing and all joints shall be water tight. Any temporary opening in the sheathing
shall be satisfactorily plugged and all joints between sheathing and any other part of the
prestressing system shall be effectively sealed to prevent entry of mortar, dust, water or
other deleterious matter. Sheathing shall be neatly fitted at joints without internal projection
or reduction of diameter.

Enlarged portions of the sheathing at couplings or anchorages shall be of sufficient length

to provide for the extension of the tendons.

1804.7 Grout Vents

Grout vents of at least 20 mm diameter shall be provided at both ends of the sheathing and
at all valleys and crests along its length. Additional vents with plugs shall also be provided
along the length of sheathing such that the spacings of consecutive vents do not exceed
20 m. Each of the grout vents shall be provided with a plug or similar device capable of
withstanding a pressure of 1.0 MPa without the loss of water, air pressure or grout.

1804.8 Anchorages

All bearing surfaces of the anchorages shall be cleaned prior to concreting and tensioning.

Anchor cones, blocks and plates shall be securely positioned and maintained during
concreting such that the center line of the duct passes axially through the anchorage
assembly.

The anchorages shall be recessed from the concrete surface by a minimum cover of 100
mm.

After the prestressing operations are completed and prestressing wires/strands are cut,
the surface shall be painted with two coats of epoxy of suitable formulation having a dry
film thickness of 80 micron per coat and entire recess shall be filled with concrete or non-
shirk/pre-packaged mortar of epoxy concrete.

1804.9 Structural Concrete

Structural concrete shall conform to Section 1700. The formwork shall conform to Section
1500.

1805 SUPERVISION

Pre-stressing operation and grouting shall be entrusted to only specially trained and qualified
personnel. All pre-stressing accessories shall be procured from authorized manufacturers
with in-house testing facilities. The Contractor shall also be required to engage specialized

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agencies who should also be entrusted with the total service contract for fabrication of
cables, protection of cables during concreting, pre-stressing and grouting. Necessary
certificates shall also be accorded by such specialized agencies that the work has been
carried out in accordance with prescribed specifications. In exceptional cases where the
employer is convinced that the Contractor of the bridge itself is well experienced and has
qualified personnel and sufficient track record to substantiate his performance in the
particular system of pre-stressing being adopted, the pre-stressing and grouting operations
could be entrusted to the contractor.

1806 TENSIONING EQUIPMENT

All tensioning equipment shall be procured from authorized manufacturers only and be
approved by the Engineer prior to use. Where hydraulic jacks are used, they shall be
power-driven unless otherwise approved by the Engineer. The tensioning equipment shall
satisfy the following requirements :

i) The means of attachments of the prestressing steel to the jack or any

other tensioning apparatus shall be safe and secure.
ii) Where two or more wires/strands constitute a tendon, a single
multipull stressing jack shall be used which is capable of tensioning
simultaneously all the wires/strands of the tendon. Suitable facilities
for handling and attaching the multipull jack to the tendons shall be
provided.
iii) The tensioning equipment shall be such that it can apply controlled
total force gradually on the concrete without inducing dangerous
secondary stressed in steel, anchorage or concrete; and
iv) Means shall be provided for direct measurement of the force by use
of dynamometers or pressure gauges fitted in the hydraulic system
itself to determine the pressure in the jacks. Facilities shall also be
provided for the liner measurement of the extension of prestressing
steel to the nearest mm and of any slip of the gripping devices at
transfer.
All dynamo meters and pressure gauges including a master gauge shall be calibrated by
an approved laboratory immediately prior to use and then at intervals not exceeding 3
months and the true force determined from the calibration curve.

Pressure gauges shall be concentric scale type gauges accurate to within two per cent of
their full capacity. The minimum nominal size of gauge shall be 100 mm. The gauge shall
be so selected that when the tendon is stressed to 75 percent of its breaking load, the
gauge is reading between 50 percent and 80 percent of its full capacity. Suitable safety
devices shall be fitted to protect pressure gauges against sudden release of pressure.

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Section 1800 Prestressing

Provision shall be made for the attachment of the master gauge to be used as a check
whenever requested for by the Engineer.

Jack & pump shall be calibrated from an approved laboratory prior to use and then at
intervals not exceeding three months.

1807 POST-TENSIONING

Tensioning force shall be applied in gradual and steady steps and carried out in such a
manner that the applied tensions and elongations can be measured at all times. The
sequence of stressing, applied tensions and elongations shall be in accordance with the
approved drawing or as directed by the Engineer.

It shall be ensured that in no case, the load is applied to the concrete before it attains the
strength specified on the drawing or as stipulated by the prestressing system supplier,
whichever is more.

After prestressing steel has been anchored, the force exerted by the tensioning equipment
shall be decreased gradually and steadily so as to avoid shock to the prestressing steel or
anchorage.

The tensioning force applied to any tendon shall be determined by direct reading of the
pressure gauges or dynamo-meters and by comparison of the measured elongation with
the calculated elongation. The calculated elongation shall be invariably adjusted with
respect to the modulus of elasticity of steel for the particular lot as given by the manufacturer.

The difference between calculated and observed tension and elongation during prestressing
operations shall be regulated as follows :

a) If the calculated elongation is reached before the specified gauge

pressure is obtained, continue tensioning till attaining the specified
gauge pressure, provided the elongation does not exceed 1.05 times
the calculated elongation. If 1.05 times the calculated elongation is
reached before the specified gauge pressure is attained, stop
stressing and inform the Engineer.
b) If the calculated elongation has not been reached at the specified
gauge pressure, continue tensioning by intervals of 5kg/sq. cm until
the calculated elongation is reached provided the gauge pressure
does not exceed 1.05 times the specified gauge pressure.
c) If the elongation at 1.05 times the specified gauge pressure is less
than 0.95 times the calculated elongation, the following measures

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must be taken, in succession, to determine the cause of this lack of

discrepancy :
i) Check the correct functioning of the jack, pump and leads.

ii) De-tension the cable. Slide it in its duct to check that it is not
blocked by mortar which has entered through holes in the
sheath. Re-tension the cable if free.

iii) Re-establish the modulus of elasticity of steel for the particular

lot from an approved laboratory.

If the required elongation is still not obtained, further finishing

operations such as cutting or sealing, should not be undertaken without
the approval of the Engineer.

d) When stressing from one end only, the slip at the end remote from
the jack shall be accurately measured and an appropriate allowance
made in the measured extension at the jacking end.
A complete record of prestressing operations along with elongation and jack pressure
data shall be maintained in the format given in Appendix 1800/II. The number of stages of
prestressing and grouting shall be reduced to a minimum, preferably two in the case of
simply supported girders.

1808 GROUTING OF PRESTRESSED TENDONS

Grouting material and operation shall conform to Appendix 5 of IRC:18.

1809 PRE-TENSIONING

1809.1 General

The planning and construction aspects of the tensioning bed, tensioning bench, abutments
at location of anchorage, steam curing system, formwork of the concrete elements and
arrangements for de-moulding, lifting, stacking and transportation of the pre-tensioned
concrete elements are all specialised items and shall be entrusted to engineers specifically
experienced in this type of work.

1809.2 Stressing Bed for Pre-tensioning

The abutments and bed for pre-tensioning of tendons shall be designed to withstand the
total tensioning force.

A notice shall be displayed adjacent to the stressing bed showing the maximum tensioning
force permitted.

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Section 1800 Prestressing

Where concrete elements are cast and prestressed individually, the stressing bench or
moulds shall be rigid enough to sustain the reaction of the prestressing force without
distortion.

In the long line method of prestressing, sufficient locator plates should be distributed
throughout the length of the bed to ensure that the wires are maintained in their proper
position during concreting. The moulds shall be free to slide in the direction of their length
and thus permit the transfer of the prestressing force to all the concrete elements along the
whole line.

Sufficient space shall be left in between the ends of concrete elements to permit access
for cutting the strands/wires after transfer. Hold-downs or deflectors shall be used for
holding or deflecting the tendons in required position firmly. Deflectors which are in contact
with the tendon shall have a diameter not less than the tendon or 15 mm, whichever is
more.

The tensioning force required to be applied as stated on the drawings shall be the force
remaining in the strands/wires after all strands/wires have been anchored to the abutments
of the stressing bed and after the anchorage slip has already taken place. The tensioning
force shall be determined by direct reading of the pressure gauges or dynamo-meters
and by the measured elongation after slip.

The Contractor shall submit method of tensioning the tendons including the arrangement
and layout of prestressing beds and all tendon deflection points to the Engineer for approval
before manufacture commences.

The Contractor shall carry out trial stressing operations to establish the frictional resistance
offered by the hold-downs and the slip during anchoring.

Where sheathing of pre-tensioned tendons is required to prevent bond over a specified

length, it shall consist of plastic tubing or other material approved by the Engineer and
shall be of a quality, diameter and thickness such that bond shall be effectively prevented.
The tubing shall be fastened to the tendon in such a manner that cement mortar cannot
enter. The Engineer may order that the pull-in of the tendon be measured during the transfer
of prestress.

The Contractor shall also submit calculation showing that the hold-downs have been
designed and constructed to withstand concentrated loads resulting from the application
of the tensioning force.

1809.3 Tensioning Procedure

The tensioning of the wires and strands shall be done not too much in advance of concreting.

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Prestressing Section 1800

The tensioning force shall be applied gradually and uniformly.

In order to remove slack and to lift tendons off the bed floor, an initial force approved by the
Engineer shall be applied to the tendons. Allowance shall be made for this force in
calculating the required elongation.

Tendons shall be marked for measurement of elongation after the initial force has been
applied. When required by the Engineer, tendons shall be marked at both the jacking end
and dead end of the stressing bed and at couplers if used so that slip and draw-in may be
measured.

Where deflected strands have been specified, the Engineer may direct the elongation or
strain gauge measurements be taken at various positions along the tendon to determine
the force in the tendon at those positions.

1809.4 Transfer of Prestress

While the process of tensioning can be accomplished by means of hydraulic jacks, some
positive mechanical means shall be provided to maintain the tension during the entire
period between the tensioning of the wires/strands and transfer of the prestressing force
to the concrete element.

Transfer of prestress shall not proceed until the Engineer has approved the proposed
method. Tendons and deflection devices shall be released in such a pre-determined order
that unacceptable tensile stresses are not induced in the concrete.

Prior to transfer of the force to the units, all tendons shall be tested for tightness and any
loose tendon shall be reported to the Engineer who will decide whether the units affected
shall be rejected.

The Engineer may require that tendons be marked at each end of any unit to allow
measurement of the pull-in of the concrete.

Tendons shall be released gradually and preferably simultaneously.

Under no circumstances shall tendons be cut while under tension.

On completion of the transfer of prestress, the projecting lengths of tendon shall be cut off
flush with the end surface of the unit, unless otherwise shown, by a method approved by
the Engineer.

In no case shall the transfer of prestressing force to the concrete elements take place
before concrete attains the strength specified in the drawings. To determine the specified

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Section 1800 Prestressing

strength, additional cube testing shall be undertaken at the Contractor’s cost. in case
steam curing is employed, the cubes shall be placed in the same environment as the
concrete elements to obtain an accurate assessment of concrete strength at the time of
transfer.

The sequence of transfer of prestressing force shall be done strictly as indicated in the
drawings and ensuring that eccentricities of the prestressing force in the vertical and
horizontal directions of the concrete element are minimum during the entire sequence.

The maximum slip of any tendon during transfer shall not exceed 3 mm at any end of the
concrete element. In case this slip is exceeded, the concrete element in question shall be
rejected.

1809.5 Protection of Ends

The exposed ends of the tendons and the concrete surfaces of the ends of the units shall
be wire brushed clean of all rust, loose mortar, grease and dirt.

The exposed ends of the tendons and concrete surface within 50 mm of tendons shall be
then abraded to provide a clean sound surface. An epoxy tar paint suitably formulated to
give a dry film thickness of 80 micron per coat shall then be immediately applied over the
ends of the tendons unless otherwise directed.

A second coat of paint shall be applied prior to the drying out of the first coat.

1810 SAFETY PRECAUTIONS DURING TENSIONING

Care shall be taken during tensioning to ensure the safety of all persons in the vicinity.

Jacks shall be securd in such a manner that they will be held in position, should they lose
their grip on the tendons.

No person shall be allowed to stand behind the jacks or closed to the line of the tendons
while tensioning is in progress.

The operations of the jacks and the measurement of the elongation and associated
operations shall be carried out in such a manner and from such a position that the safety of
all concerned is ensured.

A safety barrier shall be provided at both ends to prevent any tendon, which might become
loose from recoiling unchecked.

During actual tensioning operation, warning signs shall be displayed at both ends of the
tendon.

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After prestressing, concrete shall neither be drilled nor any portion cut nor chipped away
nor disturbed, without express approval of the Engineer.

No welding shall be permitted on or near tendons nor shall any heat be applied to tendons.
Any tendon which has been affected by welding, weld spatter or heat shall be rejected.

1811 TRANSPORTATION AND STORAGE OF UNITS

Precast girders shall be transported in an upright position. Points of support and the
direction of reactions with respect to the girder shall approximately be the same during
transportation, and storage as when the girder is placed in final position.

When members are to be stacked, they shall be firmly supported at such bearing positions
as will ensure that the stresses induced in them are always less than the permissible design
stresses. Further, inclined side supports shall be provided at the ends and along the
length of a precast girder to prevent lateral movements or instability.

Care shall be taken during storage, hoisting and handling of the precast units to prevent
their cracking or being damaged. Any unit damaged by improper storing or handling shall
be replaced by the Contractor at his cost.

1812 TOLERANCES

Permissible tolerances for positional deviation of Prestressing tendons shall be as under:

a) Variation from the specified horizontal profile : 5 mm

b) Variation from the specified vertical profile : 5 mm
c) Variation from the specified position in member : 5 mm

1813 TESTS AND STANDARDS OF ACCEPTANCE

The material shall be tested in accordance with these Specifications and shall meet the
prescribed criteria and requirements

The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.

1814 MEASUREMENTS FOR PAYMENT

Prestressed Concrete shall be measured in cubic metres. The volume occupied by mild
steel reinforcement / HYSD bars, high tensile steel, sheathing and anchorages shall not
be deducted.

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Section 1800 Prestressing

High tensile (prestressing) steel shall be paid for separately and its length shall be
measured as actually incorporated in the finished work.

From the length so measured its weight shall be calculated in tonnes on theoretical basis
and paid.

Anchorage devices, additional length of cables for attaching jack, ducts or sheathing, grout,
non-prestressed steel reinforcement fixed to the anchorage devices, making of recesses
and filling the same, protection by painting with epoxy and furnishing samples for testing
shall all be deemed to be included in the item of high tensile steel and shall not be measured
separately.

1815 RATE

The contract unit rate for cast-in-place prestressed concrete shall cover the cost of all
materials, labour, tools and plant required for mixing, placing in position, vibrating and
compacting, finishing as per directions of the Engineer, curing and other incidental expenses
for producing concrete of specified strength to complete the structure or its components
as shown on the drawings and according to Specifications. The contract unit rate shall
also include the cost of making, fixing and removing of all centering and formwork required
for the work unless otherwise specified in the Contract.

For precast prestressted concrete members, the unit rate, in addition to above, shall also
include the cost of all materials, labour, tools and plant required to transport and place
these members in their final position as shown on the drawings and as directed by the
Engineer.

The contract unit rate for high tensile steel shall cover the cost of material, labour, tools and
plant required for manufacturing, placing, tensioning, anchoring and grouting the high tensile
steel in the prestressed concrete as shown on the drawings and as per Specifications
herein above or as directed by the Engineer.

The cost of anchorage devices, additional length of cables for attaching jack, ducts or
sheathing, grout, non-prestressed steel reinforcement fixed to the anchorage devices,
making of recesses and filling the same, protection by painting with epoxy and furnishing
samples for testing shall all be included in the unit rate. Rate shall also include payments
if any to be made to the supplier of the prestessing system who has to monitor, ensure and
certify the correctness of all operations.

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